Fusion formable sodium containing glass

ABSTRACT

Sodium-containing aluminosilicate and boroaluminosilicate glasses are described herein. The glasses can be used as substrates for photovoltaic devices, for example, thin film photovoltaic devices such as CIGS photovoltaic devices. These glasses can be characterized as having strain points ≧540° C., thermal expansion coefficient of from 6.5 to 9.5 ppm/° C., as well as liquidus viscosities in excess of 50,000 poise. As such they are ideally suited for being formed into sheet by the fusion process.

This application claims the benefit of priority to U.S. Provisional Application No. 61/182,386 filed on May 29, 2009.

BACKGROUND

Field

Embodiments relate generally to sodium containing glasses and more particularly to fusion formable sodium containing glasses which may be useful in photochromic, electrochromic, Organic Light Emitting Diode (OLED) lighting, or photovoltaic applications, for example, thin film photovoltaics.

Technical Background

The fusion forming process typically produces flat glass with optimal surface and geometric characteristics useful for many electronics applications, for instance, substrates used in electronics applications, for example, display glass for LCD televisions.

Over the last 10 years, Corning fusion glass products include 1737F™, 1737G™, Eagle2000F™, EagleXG™, Jade™, and Codes 1317 and 2317 (Gorilla Glass™). Efficient melting is generally believed to occur at a temperature corresponding to a melt viscosity of about 200 poise (p). These glasses share in common 200p temperatures in excess of 1600° C., which can translate to accelerated tank and electrode corrosion, greater challenges for fining due to still more elevated finer temperatures, and/or reduced platinum system life time, particularly around the finer. Many have temperatures at 3000 poise in excess of about 1300° C., and since this is a typical viscosity for an optical stirrer, the high temperatures at this viscosity can translate to excessive stirrer wear and elevated levels of platinum defects in the body of the glass.

Many of the above described glasses have delivery temperatures in excess of 1200° C., and this can contribute to creep of isopipe refractory materials, particularly for large sheet sizes.

These attributes combine so as to limit flow (because of slow melt rates), to accelerate asset deterioration, to force rebuilds on timescales much shorter than product lifetimes, to force unacceptable (arsenic), expensive (capsule) or unwieldy (vacuum fining) solutions to defect elimination, and thus contribute in significant ways to the cost of manufacturing glass.

In applications in which rather thick, comparatively low-cost glass with less extreme properties is required, these glasses are not only overkill, but prohibitively expensive to manufacture. This is particularly true when the competitive materials are made by the float process, a very good process for producing low cost glass with rather conventional properties. In applications that are cost sensitive, such as large-area photovoltaic panels and OLED lighting, this cost differential is so large as to make the price point of LCD-type glasses unacceptable.

To reduce such costs, it is advantageous to drive down the largest overall contributors (outside of finishing), and many of these track directly with the temperatures used in the melting and forming process. Therefore, there is a need for a glass that melts at a lower temperature than those aforementioned glasses.

Further, it would be advantageous to have a glass useful for low temperature applications, for instance, photovoltaic and OLED light applications. Further, it would be advantageous to have a glass whose processing temperatures were low enough that the manufacturing of the glass would not excessively consume the energy that these applications are aiming to save.

SUMMARY

A compositional range of fusion-formable, high strain point sodium-containing aluminosilicate and boroaluminosilicate glasses useful, for example, for thin-film photovoltaic applications are described herein. More specifically, these glasses are advantageous materials to be used in copper indium gallium diselenide (CIGS) photovoltaic modules where the sodium required to optimize cell efficiency is to be derived from the substrate glass. Current CIGS module substrates are typically made from soda-lime glass sheet that has been manufactured by the float process. However, use of higher strain point glass substrates can enable higher temperature CIGS processing, which is expected to translate into desirable improvements in cell efficiency. Moreover, it may be that the smoother surface of fusion-formed glass sheets yields additional benefits, such as improved film adhesion, etc.

Accordingly, the sodium-containing glasses described herein can be characterized by strain points 540° C. so as to provide advantage with respect to soda-lime glass and/or liquidus viscosity ≦50,000 poise to allow manufacture via the fusion process. In order to avoid thermal expansion mismatch between the substrate and CIGS layer, the inventive glasses are further characterized by a thermal expansion coefficient in the range of from 6.5 to 9.5 ppm/° C. In one embodiment, the glass is fusion formable and has a strain point of 540° C. or greater, a coefficient of thermal expansion of 50×10⁻⁷ or greater, and having a liquidus viscosity of 150,000 poise or greater.

One embodiment is a glass comprising, in weight percent:

50 to 75 percent SiO₂;

1 to 20 percent Al₂O₃;

0 to 3 percent TiO₂;

0 to 10 percent B₂O₃;

8 to 25 percent total M₂O; and

0 to 50 percent total RO;

wherein, M is an alkali metal selected from Na, K, Li, Rb, and Cs and wherein the glass comprises at least 1 weight percent Na₂O; and wherein, R is an alkaline earth metal selected from Mg, Ca, Ba, and Sr.

Another embodiment is a glass consisting essentially of, in weight percent:

50 to 75 percent SiO₂;

1 to 20 percent Al₂O₃;

0 to 3 percent TiO₂;

0 to 10 percent B₂O₃;

8 to 25 percent total M₂O; and

0 to 50 percent total RO;

wherein, M is an alkali metal selected from Na, K, Li, Rb, and Cs and wherein the glass comprises at least 1 weight percent Na₂O; and wherein, R is an alkaline earth metal selected from Mg, Ca, Ba, and Sr.

A glass comprising, in weight percent:

50 to 75 percent SiO₂;

1 to 20 percent Al₂O₃;

0 to 3 percent TiO₂;

0 to 4 percent MgO;

0 to 10 percent B₂O₃;

8 to 25 percent total M₂O; and

less than 14 percent total RO;

wherein, M is an alkali metal selected from Na, K, Li, Rb, and Cs and wherein the glass comprises at least 1 weight percent Na₂O; and wherein, R is an alkaline earth metal selected from Mg, Ca, Ba, and Sr, wherein the glass is fusion formable and has a strain point of 540° C. or greater, a coefficient of thermal expansion of 50×10⁻⁷ or greater, and having a liquidus viscosity of 150,000 poise or greater.

Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from the description or recognized by practicing the invention as described in the written description and claims hereof.

It is to be understood that both the foregoing general description and the following detailed description are merely exemplary of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed.

DETAILED DESCRIPTION

Reference will now be made in detail to various embodiments of the invention.

As used herein, the term “substrate” can be used to describe either a substrate or a superstrate depending on the configuration of the photovoltaic cell. For example, the substrate is a superstrate, if when assembled into a photovoltaic cell, it is on the light incident side of a photovoltaic cell. The superstrate can provide protection for the photovoltaic materials from impact and environmental degradation while allowing transmission of the appropriate wavelengths of the solar spectrum. Further, multiple photovoltaic cells can be arranged into a photovoltaic module. Photovoltaic device can describe either a cell, a module, or both.

As used herein, the term “adjacent” can be defined as being in close proximity. Adjacent structures may or may not be in physical contact with each other. Adjacent structures can have other layers and/or structures disposed between them.

One embodiment is a glass comprising, in weight percent:

50 to 75 percent SiO₂;

1 to 20 percent Al₂O₃;

0 to 3 percent TiO₂;

0 to 10 percent B₂O₃;

8 to 25 percent total M₂O; and

0 to 50 percent total RO;

wherein, M is an alkali metal selected from Na, K, Li, Rb, and Cs and wherein the glass comprises at least 1 weight percent Na₂O; and wherein, R is an alkaline earth metal selected from Mg, Ca, Ba, and Sr.

A glass comprising, in weight percent:

50 to 75 percent SiO₂;

1 to 20 percent Al₂O₃;

0 to 3 percent TiO₂;

0 to 4 percent MgO;

0 to 10 percent B₂O₃;

8 to 25 percent total M₂O; and

less than 14 percent total RO;

-   -   wherein, M is an alkali metal selected from Na, K, Li, Rb, and         Cs and wherein the glass comprises at least 1 weight percent         Na₂O; and wherein, R is an alkaline earth metal selected from         Mg, Ca, Ba, and Sr, wherein the glass is fusion formable and has         a strain point of 540° C. or greater, a coefficient of thermal         expansion of 50×10⁻⁷ or greater, T₂₀₀ less than 1630° C., and         having a liquidus viscosity of 150,000 poise or greater.

According to one embodiment, the glass comprises:

53 to 72 percent SiO₂;

2 to 17 percent Al₂O₃;

0 to 3 percent TiO₂;

0 to 8 percent B₂O₃;

8 to 25 percent total M₂O; and

0 to 50 percent total RO.

According to another embodiment, the glass comprises:

55 to 72 percent SiO₂;

2 to 9 percent Al₂O₃;

0 to 3 percent TiO₂;

0 to 8 percent B₂O₃;

8 to 20 percent total M₂O; and

0 to 30 percent total RO;

wherein, the glass comprises at least 2 weight percent Na₂O.

In another embodiment, the glass comprises:

1 to 8 percent Na₂O;

5 to 16 percent K₂O;

0 to 8 percent MgO;

0 to 7 percent CaO;

0 to 7 percent SrO; and

0 to 21 percent BaO.

In another embodiment, the glass comprises:

2 to 5 percent Na₂O;

8 to 15 percent K₂O;

0 to 5 percent MgO;

1 to 6 percent CaO;

0 to 6 percent SrO; and

0 to 12 percent BaO.

In another embodiment, the glass comprises:

53 to 71 SiO₂;

2 to 17 Al₂O₃;

8 to 22 total M₂O; and

0 to 40 total RO;

wherein, M is an alkali metal selected from Na, K, Li, Rb, and Cs and wherein the glass comprises at least 1 weight percent Na₂O; and wherein, R is an alkaline earth metal selected from Mg, Ca, Ba, and Sr.

In another embodiment, the glass comprises:

53 to 71 SiO₂;

2 to 17 Al₂O₃;

8 to 22 total M₂O; and

0 to 40 total RO;

wherein, M is an alkali metal selected from Na, K, Li, Rb, and Cs and wherein the glass comprises at least 1 weight percent Na₂O; and wherein, R is an alkaline earth metal selected from Mg, Ca, Ba, and Sr.

In another embodiment, the glass comprises:

65 to 76 SiO₂;

1 to 7 Al₂O₃;

2.5 to 5 Na₂O;

5.5 to 11 K₂O;

0 to 8 MgO;

1 to 7 CaO; and

0 to 6 BaO.

The glass, in one embodiment, is rollable. The glass, in one embodiment, is down-drawable. The glass can be slot drawn or fusion drawn, for example. According to another embodiment the glass can be float formed.

The glass can further comprise 3 weight percent or less, for example, 0 to 3 weight percent, for example, greater than 0 to 3 weight percent, for example, 1 to 3 weight percent of TiO₂, MnO, ZnO, Nb₂O₅, MoO₃, Ta₂O₅, WO₃, ZrO₂, Y₂O₃, La₂O₃, HfO₂, CdO, SnO₂, Fe₂O₃, CeO₂, As₂O₃, Sb₂O₃, Cl, Br, or combinations thereof. In some embodiments, the glass is substantially free of ZrO₂. In some embodiments, the glass is substantially free of ZnO. The glass, in one embodiment, comprises 3 weight percent or less, for example, 0 to 3 weight percent, for example, greater than 0 to 3 weight percent, for example, 1 to 3 weight percent of TiO₂.

As mentioned above, the glasses, according some embodiments, comprise 0 to 10 weight percent, for example, greater than 0 to 10 weight percent B₂O₃, for example, 0.5 to 10 weight percent B₂O₃, for example 1 to 10 weight percent B₂O₃. B₂O₃ is added to the glass to reduce melting temperature, to decrease liquidus temperature, to increase liquidus viscosity, and to improve mechanical durability relative to a glass containing no B₂O₃.

The glass, according to one embodiment, comprises greater than 0 to 50 percent RO, for example, 0.5 to 50 percent RO, for example, 1 to 50 percent RO wherein, R is an alkaline earth metal. The glass, according to one embodiment, comprises less than 14 percent RO, for example, 0.5 to less than 14 percent RO, for example, 0.5 to 13 percent RO.

The glass can comprise, for example, 0 to 8, greater than 0 to 8 weight percent, for example, 1 to 8 weight percent MgO. The glass can comprise, for example, 0 to 5, greater than 0 to 5 weight percent, for example, 1 to 5 weight percent MgO, for example, 1 to 4 percent MgO. MgO can be added to the glass to reduce melting temperature and to increase strain point. It can disadvantageously lower CTE relative to other alkaline earths (e.g., CaO, SrO, BaO), and so other adjustments may be made to keep the CTE within the desired range. Examples of suitable adjustments include increase SrO at the expense of CaO, increasing alkali oxide concentration, and replacing a smaller alkali oxide (e.g., Na₂O) in part with a larger alkali oxide (e.g., K₂O).

According to another embodiment, the glass is substantially free of BaO. For example, the content of BaO can be 0.05 weight percent or less, for example, zero weight percent.

In some embodiments, the glass is substantially free of Sb₂O₃, As₂O₃, or combinations thereof, for example, the glass comprises 0.05 weight percent or less of Sb₂O₃ or As₂O₃ or a combination thereof. For example, the glass can comprise zero weight percent of Sb₂O₃ or As₂O₃ or a combination thereof.

The glasses, in some embodiments, comprise 0 to 7 weight percent CaO, for example, greater than 0, for example, 1 to 7 weight percent CaO, for example, 1 to 6 weight percent CaO. Relative to alkali oxides or SrO, CaO contributes to higher strain point, lower density, and lower melting temperature. It is a primary component of certain possible denitrification phases, particularly anorthite (CaAl₂Si₂O₈), and this phase has complete solid solution with an analogous sodium phase, albite (NaAlSi₃O₈). High Na and Ca contents taken alone can cause liquidus temperatures to be unacceptably high. However, the chemical sources for CaO include limestone, a very inexpensive material, so to the extent that high volume and low cost are factors, it is typically useful to make the CaO content as high as can be reasonably achieved relative to other alkaline earth oxides.

The glasses can comprise, in some embodiments, 0 to 7 weight percent SrO, for example, greater than zero to 7 weight percent, for example, 1 to 7 weight percent SrO, or for example, 0 to 6 weight percent SrO, for example, greater than zero to 6 weight percent, for example, 1 to 6 weight percent SrO. In some embodiments, the glass comprises less than 15 weight percent SrO, for example, 1 to 12 weight percent SrO. In certain embodiments, the glass contains no deliberately batched SrO, though it may of course be present as a contaminant in other batch materials. SrO contributes to higher coefficient of thermal expansion, and the relative proportion of SrO and CaO can be manipulated to improve liquidus temperature, and thus liquidus viscosity. SrO is not as effective as CaO or MgO for improving strain point, and replacing either of these with SrO tends to cause the melting temperature to increase.

Also as mentioned above, the glasses, according to some embodiments, include 8 to 25 percent M₂O, for example, 8 to 22 M₂O, 8 to 20 M₂O, where M is one of the alkali cations Li, Na, K, Rb and Cs. The alkali cations raise the CTE steeply, but also lower the strain point and, depending upon how they are added, increase melting temperatures. The least effective alkali oxide for CTE is Li₂O, and the most effective alkali oxide is Cs₂O. As noted above, sodium can participate in one of the possible denitrification phases of the inventive glasses, and while adjustments in other components can be used to counteract this, e.g., changing the CaO/(CaO+SrO) ratio, this tendency may make it advantageous to replace sodium with other alkalis, or to use a mix of alkalis instead of sodium alone. If high volume and low cost are important, then it is desirable to as much as possible confine the alkali oxides to Na₂O and K₂O or combinations thereof.

In one embodiment, the glass comprises 1 to 8 weight percent Na₂O, for example, 2 to 8 weight percent Na₂O, for example, 3 to 8 weight percent Na₂O, for example, 4 to 8 weight percent Na₂O. In another embodiment, the glass comprises 1 to 5 weight percent Na₂O, for example, 1 to 4 weight percent Na₂O, for example, 1 to 3 weight percent Na₂O, for example, 1 to 2 weight percent Na₂O.

In some embodiments, the weight percent of the combination of Na₂O and K₂O is greater than 3 percent, for example, greater than 5 percent, for example, greater than 10 percent, for example, greater than 12 percent.

Another embodiment is a glass consisting essentially of, in weight percent:

50 to 75 percent SiO₂;

1 to 20 percent Al₂O₃;

0 to 3 percent TiO₂;

0 to 10 percent B₂O₃;

8 to 25 percent total M₂O; and

0 to 50 percent total RO;

wherein, M is an alkali metal selected from Na, K, Li, Rb, and Cs and wherein the glass comprises at least 1 weight percent Na₂O; and wherein, R is an alkaline earth metal selected from Mg, Ca, Ba, and Sr.

The glass, according to some embodiments, is down-drawable; that is, the glass is capable of being formed into sheets using down-draw methods such as, but not limited to, fusion draw and slot draw methods that are known to those skilled in the glass fabrication arts. Such down-draw processes are used in the large-scale manufacture of ion-exchangeable flat glass.

The fusion draw process uses a drawing tank that has a channel for accepting molten glass raw material. The channel has weirs that are open at the top along the length of the channel on both sides of the channel. When the channel fills with molten material, the molten glass overflows the weirs. Due to gravity, the molten glass flows down the outside surfaces of the drawing tank. These outside surfaces extend down and inwardly so that they join at an edge below the drawing tank. The two flowing glass surfaces join at this edge to fuse and form a single flowing sheet. The fusion draw method offers the advantage that, since the two glass films flowing over the channel fuse together, neither outside surface of the resulting glass sheet comes in contact with any part of the apparatus. Thus, the surface properties are not affected by such contact.

The slot draw method is distinct from the fusion draw method. Here the molten raw material glass is provided to a drawing tank. The bottom of the drawing tank has an open slot with a nozzle that extends the length of the slot. The molten glass flows through the slot/nozzle and is drawn downward as a continuous sheet therethrough and into an annealing region. Compared to the fusion draw process, the slot draw process provides a thinner sheet, as only a single sheet is drawn through the slot, rather than two sheets being fused together, as in the fusion down-draw process.

In order to be compatible with down-draw processes, the aluminoborosilicate glass described herein has a high liquidus viscosity. In one embodiment, the glass has a liquidus viscosity of 50,000 poise or greater, for example, 150,000 poise or greater, for example, 200,000 poise or greater, for example, 250,000 poise or greater, for example, 300,000 poise or greater, for example, 350,000 poise or greater, for example, 400,000 poise or greater, for example, greater than or equal to 500,000 poise. The liquidus viscosities of some exemplary glasses are closely correlated with the difference between the liquidus temperature and the softening point. For downdraw processes, some exemplary glasses advantageously have liquidus—softening point less than about 230° C., for example, less than 200° C.

Accordingly, in one embodiment, the glass has a strain point of 540° C. or greater, for example, 540° C. to 600° C. In some embodiments, the glass has a coefficient of thermal expansion of 50×10⁻⁷ or greater, for example, 60×10⁻⁷ or greater, for example, 70×10⁻⁷ or greater, for example, 80×10⁻⁷ or greater. In one embodiment, the glass has a strain point of from 50×10⁻⁷ to 90×10⁻⁷.

In one embodiment, the glass has a coefficient of thermal expansion of 50×10⁻⁷ or greater and a strain point of 540° C. or greater.

According to one embodiment, the glass is ion exchanged in a salt bath comprising one or more salts of alkali ions. The glass can be ion exchanged to change its mechanical properties. For example, smaller alkali ions, such as lithium or sodium, can be ion-exchanged in a molten salt containing one or more larger alkali ions, such as sodium, potassium, rubidium or cesium. If performed at a temperature well below the strain point for sufficient time, a diffusion profile will form in which the larger alkali moves into the glass surface from the salt bath, and the smaller ion is moved from the interior of the glass into the salt bath. When the sample is removed, the surface will go under compression, producing enhanced toughness against damage. Such toughness may be desirable in instances where the glass will be exposed to adverse environmental conditions, such as photovoltaic grids exposed to hail. A large alkali already in the glass can also be exchanged for a smaller alkali in a salt bath. If this is performed at temperatures close to the strain point, and if the glass is removed and its surface rapidly reheated to high temperature and rapidly cooled, the surface of the glass will show considerable compressive stress introduced by thermal tempering. This will also provide protection against adverse environmental conditions. It will be clear to one skilled in the art that any monovalent cation can be exchanged for alkalis already in the glass, including copper, silver, thallium, etc., and these also provide attributes of potential value to end uses, such as introducing color for lighting or a layer of elevated refractive index for light trapping.

According to another embodiment, the glass can be float formed as known in the art of float forming glass.

In one embodiment, the glass is in the form of a sheet. The glass in the form of a sheet can be thermally tempered.

In one embodiment, an Organic Light Emitting Diode device comprises the glass in the form of a sheet.

The glass, according to one embodiment, is transparent.

In one embodiment, a photovoltaic device comprises the glass in the form of a sheet. The photovoltaic device can comprise more than one of the glass sheets, for example, as a substrate and/or as a superstrate. In one embodiment, the photovoltaic device comprises the glass sheet as a substrate and/or superstrate, a conductive material adjacent to the substrate, and an active photovoltaic medium adjacent to the conductive material. In one embodiment, the active photovoltaic medium comprises a CIGS layer. In one embodiment, the active photovoltaic medium comprises a cadmium telluride (CdTe) layer. In one embodiment, the photovoltaic device comprises a functional layer comprising copper indium gallium diselenide or cadmium telluride. In one embodiment, the photovoltaic device the functional layer is copper indium gallium diselenide. In one embodiment, the functional layer is cadmium telluride.

In one embodiment, the glass sheet is transparent. In one embodiment, the glass sheet as the substrate and/or superstrate is transparent.

According to some embodiments, the glass sheet has a thickness of 4.0 mm or less, for example, 3.5 mm or less, for example, 3.2 mm or less, for example, 3.0 mm or less, for example, 2.5 mm or less, for example, 2.0 mm or less, for example, 1.9 mm or less, for example, 1.8 mm or less, for example, 1.5 mm or less, for example, 1.1 mm or less, for example, 0.5 mm to 2.0 mm, for example, 0.5 mm to 1.1 mm, for example, 0.7 mm to 1.1 mm. Although these are exemplary thicknesses, the glass sheet can have a thickness of any numerical value including decimal places in the range of from 0.1 mm up to and including 4.0 mm.

In one embodiment, an electrochromic device comprises the glass in the form of a sheet. The electrochromic device can be, for example, an electrochromic window. In one embodiment, the electrochromic window comprises one or more of the glass sheets, such as in a single, double, or triple pane window.

The fusion formable glasses of this invention, by virtue of their relatively high strain point, represent advantaged substrate materials for CIGS photovoltaic modules. When manufactured by the fusion process, their superior surface quality relative to that of float glass may also result in further improvements to the photovoltaic module making process. Advantageous embodiments of this invention are characterized by liquidus viscosity in excess of 400,000 poise, thereby enabling the fabrication of the relatively thick glass sheet that may be required by some module manufacturers. Finally, the most advantageous embodiments of this invention comprise glasses for which the 200 poise temperature is less than 1580° C., providing for the possibility of significantly lower cost melting/forming.

EXAMPLES

The following is an example of how to fabricate a sample of an exemplary glass, according to one embodiment of the invention, as shown in Table 1. This composition corresponds to composition number 12 shown in Table 4.

TABLE 1 oxide mol % SiO₂ 74.75 Al₂O₃ 1.76 MgO 5.23 CaO 5.66 SrO 2.78 Na₂O 3.00 K₂O 6.72 SnO₂ 0.10 In some embodiments, the total does not add up to 100%, since certain tramp elements are present at non-negligible concentrations.

Batch materials, as shown in Table 2 were weighed and added to a 4 liter plastic container:

TABLE 2 Batch Components batch weight sand 1656.84 alumina 65.71 Magnesia 79.80 Limestone 221.90 Strontium carbonate 161.38 Sodium carbonate 117.06 Potassium carbonate 353.91 10% SnO₂ and 90% sand 57.6

It should be appreciated that in the batch, limestone, depending on the source can contain tramp elements and/or vary amounts of one or more oxides, for example, MgO and/or BaO. The sand is advantageously beneficiated so that at least 80% by mass passes 60 mesh, for example 80 mesh, for example 100 mesh. The SnO₂ added, in this example, was pre-mixed with sand at a level of 10% by weight so as to ensure homogeneous mixing with the other components. The bottle containing the batch materials was mounted to a tumbler and the batch materials were mixed so as to make a homogeneous batch and to break up soft agglomerates. The mixed batch was transferred to a 1800 cc platinum crucible and placed into a high-temperature ceramic backer. The platinum in its backer was loaded into a glo-bar furnace idling at a temperature of 1600° C. After 16 hours, the crucible+backer was removed and the glass melt was poured onto a cold surface, such as a steel plate, to form a patty, and then transferred to an annealer held at a temperature of 615° C. The glass patty was held at the annealer temperature for 2 hours, then cooled at a rate of 1° C. per minute to room temperature.

Table 3, Table 4, Table 5, Table 6, Table 7, Table 8, and Table 9 show exemplary glasses, according to embodiments of the invention, and made according to the above example. Properties data for some exemplary glasses are also shown in Table 3, Table 4, Table 5, Table 6, Table 7, Table 8, and Table 9.

In the Tables T_(str)(° C.) is the strain point which is the temperature when the viscosity is equal to 10^(14.7) P as measured by beam bending or fiber elongation. T_(ann)(° C.) is the annealing point which is the temperature when the viscosity is equal to 10^(13.18) P as measured by beam bending or fiber elongation. T_(s)(° C.) is the softening point which is the temperature when the viscosity is equal to 10^(7.6) P as measured by beam bending or fiber elongation. α(10⁻⁷/° C.) or a(10⁻⁷/° C.) in the Tables is the coefficient of thermal expansion (CTE) which is the amount of dimensional change from either 0 to 300° C. or 25 to 300° C. depending on the measurement. CTE is typically measured by dilatometry. r(g/cc) is the density which is measured with the Archimedes method (ASTM C693). T₂₀₀(° C.) is the two-hundred Poise (P) temperature. This is the temperature when the viscosity of the melt is 200P as measured by HTV (high temperature viscosity) measurement which uses concentric cylinder viscometry. T_(liq)(° C.) is the liquidus temperature. This is the temperature where the first crystal is observed in a standard gradient boat liquidus measurement (ASTM C829-81). Generally this test is 72 hours but can be as short as 24 hours to increase throughput at the expense of accuracy (shorter tests could underestimate the liquidus temperature). η_(liq)(° C.) is the liquidus viscosity. This is the viscosity of the melt corresponding to the liquidus temperature.

TABLE 3 Example 1 2 3 4 5 6 7 8 9 10 11 Composition (mol %) Na₂O 6 2 3 3 2 3 3.92 3.92 3.16 3.16 3.14 K₂O 6 10 9 9 10.5 9.5 7.83 7.83 10.03 9.03 9.95 MgO 5.74 5.74 6.25 5.5 11 11 5.63 5.62 7.08 7.07 7.02 CaO 2.23 2.23 6.75 5.9 3.1 3.1 3.43 3.43 3.27 3.93 3.25 SrO 1.55 1.55 3.3 2.9 1 1 2.35 2.35 1.05 1.39 1.04 BaO 0 0 2 4 0 0 0 0 0 0 0 TiO₂ 0 0 0 0 0 0 0 0 0 0 0 B₂O₃ 0.8 0.8 0 0 1.65 1.65 0.78 0.78 0.72 0.72 1.5 Al₂O₃ 4.8 4.8 2.35 2.35 3.15 3.15 4.7 6.66 4.34 4.35 5.3 SiO₂ 72.81 72.81 67.25 67.25 67.5 67.5 71.29 69.34 70.25 70.25 68.7 SnO₂ 0.07 0.07 0.1 0.1 0.1 0.1 0.07 0.07 0.1 0.1 0.1 Composition (wt %) Na₂O 5.81 1.9 2.81 2.73 1.95 2.94 3.74 3.7 3.03 3.04 2.99 K₂O 8.84 14.5 12.8 12.5 15.6 14.2 11.4 11.3 14.7 13.2 14.4 MgO 3.62 3.55 3.81 3.26 6.98 7.03 3.51 3.46 4.43 4.44 4.36 CaO 1.96 1.92 5.73 4.87 2.74 2.76 2.97 2.94 2.84 3.43 2.81 SrO 2.52 2.47 5.18 4.42 1.64 1.65 3.76 3.72 1.69 2.24 1.66 BaO 0 0 4.64 9.02 0 0 0 0 0 0 0 TiO₂ 0 0 0 0 0 0 0 0 0 0 0 B₂O₃ 0.87 0.86 0 0 1.81 1.82 0.84 0.83 0.78 0.78 1.61 Al₂O₃ 7.66 7.51 3.63 3.53 5.07 5.09 7.4 10.4 6.86 6.9 8.32 SiO₂ 68.5 67.1 61.1 59.4 63.9 64.2 66.2 63.5 65.4 65.7 63.5 SnO₂ 0.17 0.16 0.23 0.22 0.24 0.24 0.16 0.16 0.23 0.23 0.23 T_(str) (° C.) 548 581 552 544 573 559 560 577 560 567 562 T_(ann) (° C.) 595 632 599 591 622 607 609 627 611 617 612 T_(s) (° C.) 824 879 796 787 a (10⁻⁷/° C.) 79.2 80.5 90.4 92.5 83 83.9 82.2 82.2 r (gm/cc) 2.457 2.448 2.635 2.699 2.474 2.479 2.489 2.497 2.467 2.476 2.469 T₂₀₀ (° C.) 1392 1499 1575 1616 1581 1569 1570 T_(liq) (° C.) 970 995 1015 970 1115 1060 1000 1100 1035 1062 1077 h_(liq) (kp) 105 56 351 88 175 101 71

TABLE 4 Example 12 13 14 15 16 17 18 19 20 21 22 Composition (mol %) Na₂O 3 3 3 3 3 3 3.75 3.75 3.75 4.61 3.95 K₂O 7.17 7.17 6.97 6.65 6.59 6.59 6.96 6.69 6.43 6 7.89 MgO 6.59 6.59 6.47 5.18 5.13 5.13 5.01 4.82 4.63 4.31 6.67 CaO 5.54 5.54 5.42 5.6 5.55 5.55 5.41 5.2 4.99 4.66 3.46 SrO 2.47 2.47 2.41 2.75 2.72 2.72 3.67 3.53 3.38 3.16 2.37 BaO 0 0 0 1 2 2 0 0 0 0 0 TiO₂ 0 0 0 0 0 0 0 0 0 0 0 B₂O₃ 0 0 0 0 0 0 0.7 0.67 0.64 0.6 0 Al₂O₃ 1.88 3.38 2.38 2.74 1.72 2.72 4.18 4.02 3.86 5.3 4.39 SiO₂ 73.25 71.75 73.25 72.98 73.19 72.19 70.24 71.24 72.24 71.28 71.2 SnO₂ 0.1 0.1 0.1 0.1 0.1 0.1 0.08 0.08 0.08 0.08 0.07 Composition (wt %) Na₂O 2.94 2.91 2.94 2.87 2.85 2.83 3.58 3.59 3.6 4.39 3.8 K₂O 10.7 10.6 10.4 9.7 9.54 9.48 10.1 9.74 9.39 8.7 11.6 MgO 4.22 4.17 4.13 3.24 3.18 3.16 3.12 3.01 2.9 2.68 4.18 CaO 4.93 4.88 4.81 4.87 4.79 4.76 4.67 4.51 4.34 4.03 3.02 SrO 4.07 4.02 3.96 4.42 4.34 4.31 5.86 5.65 5.42 5.04 3.82 BaO 0 0 0 2.38 4.72 4.69 0 0 0 0 0 TiO₂ 0 0 0 0 0 0 0 0 0 0 0 B₂O₃ 0 0 0 0 0 0 0.75 0.72 0.69 0.64 0 Al₂O₃ 3.04 5.42 3.84 4.33 2.7 4.24 6.57 6.33 6.1 8.32 6.95 SiO₂ 69.8 67.7 69.6 67.9 67.6 66.3 65.1 66.2 67.3 65.9 66.5 SnO₂ 0.24 0.24 0.24 0.23 0.23 0.23 0.19 0.19 0.19 0.19 0.16 T_(str) (° C.) 567 580 573 569 557 567 563 563 563 565 564 T_(ann) (° C.) 618 632 623 620 607 617 611 611 611 614 615 T_(s) (° C.) a (10⁻⁷/° C.) 79 78.8 79.2 78.5 79.9 79.9 81.7 81.1 78.9 79.4 83.3 r (gm/cc) 2.496 2.503 2.494 2.541 2.584 2.584 2.541 2.529 2.521 2.516 2.494 T₂₀₀ (° C.) 1542 1570 1559 1549 ~1520 1529 ~1530 1546 ~1565 1585 1585 T_(liq) (° C.) 1020 1075 1030 1045 955 1015 1055 1055 1050 1030 1020 h_(liq) (kp) 194 92 190 121 ~630 194 ~70 80 ~110 175 292

TABLE 5 Example 23 24 25 26 27 28 29 30 31 32 33 Composition (mol %) Na₂O 3.1 3.12 3.62 3.2 3.33 3.02 4.3 4 3 3.98 4.3 K₂O 8.59 8.64 7.25 10.14 7.52 6.82 7.6 4.93 6 6.88 9.75 MgO 10.06 10.11 6.25 5 3.12 2.86 3.3 4.22 0 9.06 4.5 CaO 2.85 2.86 4.55 3.31 5.22 4.73 5.6 7.77 0 2.56 1.75 SrO 0.91 0.91 2.18 1.07 0.36 0.34 1 2.4 0.21 1.76 0.8 BaO 0 0 0 0 0 0 0 1.43 10.12 1.44 1.05 TiO₂ 0 0 0 0 0 0 0 0 0 0 1 B₂O₃ 1.51 1 1 1.76 2.71 2.46 2.4 2.51 7.83 0.88 1.15 Al₂O₃ 2.88 2.9 4.8 5.36 4.59 4.54 7.2 5.42 6 4.44 7.1 SiO₂ 70 70.36 70.25 70.08 73.06 75.24 68.5 66.89 66.83 68.9 68.6 SnO₂ 0.15 0.15 0.1 0.08 0.1 0.1 0.1 0.1 0.1 0.1 0 Composition (wt %) Na₂O 3.05 3.07 3.48 3.02 3.21 2.91 4.05 3.78 2.47 3.8 3.96 K₂O 12.9 13 10.6 14.6 11 10 10.9 7.09 7.52 10 13.7 MgO 6.46 6.49 3.92 3.08 1.96 1.8 2.03 2.6 0 5.64 2.7 CaO 2.54 2.56 3.97 2.84 4.56 4.13 4.78 6.66 0 2.22 1.46 SrO 1.5 1.5 3.51 1.7 0.58 0.54 1.58 3.8 0.29 2.82 1.23 BaO 0 0 0 0 0 0 0 3.35 20.7 3.41 2.4 TiO₂ 0 0 0 0 0 0 0 0 0 0 1.19 B₂O₃ 1.67 1.11 1.08 1.87 2.94 2.67 2.55 2.67 7.26 0.95 1.19 Al₂O₃ 4.68 4.71 7.61 8.35 7.29 7.22 11.2 8.44 8.14 6.99 10.8 SiO₂ 66.9 67.3 65.6 64.3 68.4 70.5 62.7 61.4 53.4 63.9 61.4 SnO₂ 0.24 0.24 0.23 0.18 0.02 0.23 0.23 0.23 0.2 0.23 0 T_(str) (° C.) 560 561 571 562 561 571 565 568 551 562 553 T_(ann) (° C.) 609 611 620 611 607 621 610 612 590 608 601 T_(s) (° C.) 831 a (10⁻⁷/° C.) 81.6 82.4 79.7 86 76.7 69.9 80.2 75.7 74.9 79.1 87.3 r (gm/cc) 2.462 2.462 2.498 2.463 2.445 2.421 2.472 2.582 2.796 2.538 2.498 T₂₀₀ (° C.) 1558 1549 1595 1610 1613 1660 1584 1410 1548 1623 T_(liq) (° C.) 1065 1070 1095 1010 1020 1040 1070 1090 930 1050 1100 h_(liq) (kp) 90 81 71 344 142 270 69 124 110 67

TABLE 6 Example 34 35 36 37 38 39 40 41 42 43 44 Composition (mol %) Na₂O 4.2 3.5 4.2 4.2 3 3 3.3 4 4 6.42 7.15 K₂O 6.2 7.5 6.2 6.2 7 7 6.8 7.5 6.5 6.06 5.7 MgO 6 0 6 6 5.4 5.4 5.5 4.9 5.3 0 0 CaO 2.3 0 2.3 2.3 5.8 5.8 4.9 4.9 5.3 5.34 5.7 SrO 1.6 0.18 1.6 1.6 2.9 2.9 2.6 0.05 0.05 0.05 0.04 BaO 2.1 8.62 2.1 2.1 0 0 0.5 2.35 2.55 2.29 1.91 TiO₂ 1 0 2 2 2 2 2 0 0 0 0 B₂O₃ 0.8 6.6 0.8 0.8 0 0 0.2 0.8 0.8 3.36 2.8 Al₂O₃ 5 6 6 7 1.9 2.9 3.4 7 7 9.8 11 SiO₂ 70.8 67.6 68.8 67.8 72 71 70.8 68.5 68.5 65.48 64.7 SnO₂ 0 0 0 0 0 0 0 0 0 0 0 Composition (wt %) Na₂O 3.93 2.92 3.9 3.87 2.91 2.89 3.16 3.7 3.72 5.76 6.42 K₂O 8.85 9.55 8.77 8.71 10.4 10.3 9.91 10.6 9.2 8.29 7.81 MgO 3.66 0 3.63 3.61 3.42 3.4 3.43 2.96 3.21 0 0 CaO 1.95 0 1.94 1.92 5.11 5.07 4.25 4.12 4.47 4.35 4.65 SrO 2.51 0.25 2.49 2.47 4.72 4.69 4.17 0.08 0.08 0.08 0.06 BaO 4.88 17.9 4.83 4.8 0 0 1.19 5.4 5.88 5.1 4.26 TiO₂ 1.21 0 2.4 2.38 2.51 2.49 2.47 0 0 1.39 1.16 B₂O₃ 0.84 6.21 0.84 0.83 0 0 0.22 0.83 0.84 3.4 2.83 Al₂O₃ 7.72 8.27 9.18 10.6 3.04 4.61 5.37 10.7 10.7 14.5 16.3 SiO₂ 64.4 54.9 62 60.8 67.9 66.6 65.8 61.6 61.9 57.1 56.5 SnO₂ 0 0 0 0 0 0 0 0 0 0 0 T_(str) (° C.) 563 546 571 580 567 574 568 567 574 555 559 T_(ann) (° C.) 611 585 618 628 615 622 616 617 623 599 603 T_(s) (° C.) a (10⁻⁷/° C.) 77.2 80.5 77.3 76.9 77.2 77 77.3 83.1 78 81.1 82.9 r (gm/cc) 2.546 2.747 2.565 2.566 2.525 2.532 2.538 2.536 2.547 2.543 2.537 T₂₀₀ (°C) 1597 1423 1595 1603 1513 1536 1555 1596 1587 1571 1611 T_(liq) (° C.) 1000 950 1040 1070 1015 1065 1020 1100 1125 1030 1060 h_(liq) (kp) 364 78 164 111 140 67 162 65 43 98 106

TABLE 7 Example 45 46 47 48 49 50 51 Composition (mol %) Na₂O 4 4 4.3 3.93 3.95 3.2 2.95 K₂O 8 6 6.45 7.86 7.89 9.81 9.04 MgO 5.74 5.74 6.16 5.65 5.67 0.51 0.46 CaO 2.23 2.23 2.39 3.44 3.46 5.09 4.69 SrO 1.55 1.55 1.65 2.36 2.37 0 0 BaO 0 2 2.15 0 0 0 0 TiO₂ 0 0 0 0 0 0 0 B₂O₃ 0.8 0.8 0.86 0.4 0 2.34 2.15 Al₂O₃ 4.8 4.8 5.15 4.72 4.74 5.06 4.97 SiO₂ 72.81 72.78 70.78 71.57 71.85 74.01 75.65 SnO₂ 0.07 0.1 0.1 0.07 0.07 0.1 0.1 Composition (wt %) Na₂O 3.83 3.76 4.02 3.75 3.77 3.02 2.79 K₂O 11.7 8.6 9.18 11.4 11.5 14.1 13 MgO 3.59 3.52 3.76 3.52 3.53 0.31 0.28 CaO 1.94 1.9 2.03 2.98 3 4.35 4.02 SrO 2.49 2.45 2.61 3.78 3.8 0 0 BaO 0 4.67 4.99 0 0 0 0 TiO₂ 0 0 0 0 0 0 0 B₂O₃ 0.86 0.85 0.91 0.43 0 2.49 2.29 Al₂O₃ 7.59 7.45 7.93 7.43 7.47 7.87 7.76 SiO₂ 67.8 66.5 64.3 66.4 66.7 67.8 69.6 SnO₂ 0.16 0.23 0.23 0.16 0.16 0.02 0.23 T_(str) (° C.) 560 560 555 558 564 560 565 T_(ann) (° C.) 609 614 605 608 616 605 613 T_(s) (° C.) 846 856 839 a (10⁻⁷/° C.) 80.4 75.3 77.7 83.2 83.3 80.7 77.4 r (gm/cc) 2.521 2.528 2.551 2.489 2.488 2.435 2.425 T₂₀₀ (° C.) 1630 1613 1588 1607 1622 1603 1660 T_(liq) (° C.) 930 990 1000 905 990 910 930 h_(liq) (kp) 2843 705 429 5378 781 1524 1679

TABLE 8 Example 52 53 54 55 56 57 58 59 Composition (mol %) Na₂O 3.13 3.2 3 3.95 4.5 4.2 3.5 3.5 K₂O 9.93 10.14 6.72 7.89 6 6.2 7.5 7.5 MgO 7 5 5.23 5.67 1.6 6 0 0 CaO 3.24 3.31 5.66 3.46 3.4 2.3 3.9 3.9 SrO 1.04 1.07 2.78 3.37 0.1 1.6 0.08 0.08 BaO 0 0 0 0 5.2 2.1 3.82 3.82 TiO₂ 0 0 0 0 0 2 2 2 B₂O₃ 1.72 1.76 0 0 7.1 0.8 5.6 5.6 Al₂O₃ 3.29 3.36 1.76 4.39 6 5 5 6 SiO₂ 70.55 72.06 74.75 71.2 66.1 69.8 68.6 67.6 SnO₂ 0.1 0.1 0.1 0.07 0 0 0 0 Composition (wt %) Na₂O 3.02 3.06 2.93 3.76 3.98 3.92 3.13 3.11 K₂O 14.6 14.8 10 11.4 8.09 8.82 10.2 10.2 MgO 4.4 3.12 3.34 3.52 0.92 3.65 0 0 CaO 2.83 2.87 5.01 2.99 2.73 1.95 3.16 3.14 SrO 1.68 1.72 4.56 5.37 0.15 2.5 0.12 0.12 BaO 0 0 0 0 11.4 4.86 8.47 8.42 TiO₂ 0 0 0 0 0 2.41 2.31 2.3 B₂O₃ 1.87 1.9 0 0 7.08 0.84 5.64 5.6 Al₂O₃ 5.23 5.3 2.84 6.88 8.76 7.7 7.37 8.79 SiO₂ 66.1 67 71 65.8 56.9 63.3 59.6 58.4 SnO₂ 0.24 0.23 0.24 0.16 0 0 0 0 T_(str) (° C.) 553 549 565 559 540 564 549 549 T_(ann) (° C.) 600 597 615 609 580 611 589 590 T_(s) (° C.) a (10⁻⁷/° C.) 84.8 86.3 77.4 84.8 78 76.2 77.5 77.9 r (gm/cc) 2.466 2.463 2.498 2.52 2.468 2.559 2.604 2.601 T₂₀₀ (° C.) 1529 1553 1568 1578 1425 1566 1476 1485 T_(liq) (° C.) 910 845 995 980 865 980 880 900 h_(liq) (kp) 1693 9012 422 514 650 468 933 518

TABLE 9 Example 60 61 62 Composition (mol %) Na₂O 3.2 3.07 3.71 K₂O 9.14 8.77 7.16 MgO 5 4.8 5.28 CaO 4.06 3.89 4.77 SrO 1.32 1.27 0.94 BaO 0 0 4 TiO₂ 0 0 0 B₂O₃ 1.76 5.76 1.55 Al₂O₃ 5.36 5.14 4.71 SiO₂ 70.08 67.23 67.8 SnO₂ 0.08 0.08 0.08 Composition (wt %) Na₂O 3.03 2.9 3.39 K₂O 13.21 12.63 9.96 MgO 3.09 2.96 3.14 CaO 3.49 3.34 3.95 SrO 2.1 2.02 1.44 BaO 0 0 9.06 TiO₂ 0 0 0 B₂O₃ 1.88 6.14 1.59 Al₂O₃ 8.39 8.01 7.09 SiO₂ 64.6 61.77 60.16 SnO₂ 0.18 0.18 0.18 T_(str) (° C.) 565 558 561 T_(ann) (° C.) 614 602 609 T_(s) (° C.) a (10⁻⁷/° C.) 83.3 75.2 78 r (gm/cc) 2.472 2.46 2.63 T₂₀₀ (° C.) 1601 1537 1514 T_(liq) (° C.) 1000 1020 980 h_(liq) [kp) 405 104 257

It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. 

What is claimed is:
 1. A glass comprising, in weight percent: 65 to 75 percent SiO₂; 1 to 20 percent Al₂O₃; 0 to 3 percent TiO₂; 0 to 8 percent B₂O₃; 12 to 25 percent total M₂O; 2 to 5 percent Na₂O; 8 to 15 percent K₂O; 1 to 6 percent CaO; and 1 to 29 percent total RO; and greater than 4 to 7 percent SrO, wherein, M is an alkali metal selected from Na, K, Li, Rb, and Cs, wherein R is an alkaline earth metal selected from Mg, Ba, Ca, and Sr, wherein the glass has a strain point of 540° C. or greater, wherein the glass has a liquidus viscosity greater than 50,000 poise, wherein the glass has a specific gravity greater than 2.42 and less than 2.60, and wherein said glass comprises less than or equal to 0.05% by weight of ZrO₂.
 2. The glass according to claim 1, wherein the glass is fusion formable and has a strain point of 540° C. or greater, a coefficient of thermal expansion of 50×10⁻⁷ /° C. or greater, T₂₀₀ less than 1630° C., and a liquidus viscosity of 150,000 poise or greater.
 3. The glass according to claim 1, wherein the glass is free of ZrO₂.
 4. The glass according to claim 1, having a T₂₀₀ less than 1580° C. and a liquidus viscosity of 400,000 poise or greater.
 5. The glass according to claim 1, comprising: 2 to 17 Al₂O₃.
 6. The glass according to claim 1, wherein the glass is in the form of a sheet.
 7. The glass according to claim 6, wherein the sheet has a thickness in the range of from 0.5 mm to 3.0 mm.
 8. A photovoltaic device comprising the glass according to claim
 1. 9. The photovoltaic device according to claim 8, wherein the glass is in the form of a sheet and is a substrate or a superstrate.
 10. The photovoltaic device according to claim 9, comprising a functional layer comprising copper indium gallium diselenide or cadmium telluride adjacent to the substrate or superstrate.
 11. A glass consisting essentially of, in weight percent: 65 to 75 percent SiO₂; 2 to 17 percent Al₂O₃; 0 to 3 percent TiO₂; greater than 0 to 8 percent B₂O₃; 8 to 25 percent total M₂O; 2 to 5percent Na₂O; 8 to 15 percent K₂O; 0 to 5 percent MgO; 1 to 6 percent CaO; greater than 4 to 6 percent SrO; greater than 0 to 3 percent SnO₂; and 0 to 4 percent BaO; wherein, M is an alkali metal selected from Na, K, Li, Rb, and Cs, and wherein the glass has a strain point of 540° C. or greater, a specific gravity of less than 2.60 and greater than 2.42, and a liquidus viscosity of greater than 50,000 poise, and wherein the glass is substantially free of ZrO₂. 